Insert molded tamper evident pouring spout

ABSTRACT

A flexible pouring spout for material containers incorporating a tamper evident ring having the container cover molded around the peripheral edge of the spout and ring to integrally bond both the spout and its tamper-evident ring within the cover. The closure spout generally includes a dispensing orifice and a cap member for selectively closing the spout. A tamper evident ring is connected to the cap member by a series of frangible elements. Both the spout and the tamper evident ring include peripheral flanges which are molded directly within the container cover upon formation of the cover. The spout and cap with its tamper evident ring are inserted into the mold for the container cover with the peripheral flanges extending pivotally into the mold for the cover. Upon molding the cover, the molten plastic will envelope the flanges creating an integral bond with both the spout and tamper-evident, creating dual tamper evidence for the container closure. Both the mold and the preferred closure include structural features which prevent molten plastic from flowing between the flanges of the spout and tamper ring thereby eliminating deformation of the closure during molding of the container cover by reducing the force of the molten plastic directly on the closure.

This is a continuation-in-part application of U.S. Patent ApplicationSer. No. 08/906,282 filed on Aug. 5, 1997.

BACKGROUND OF THE INVENTION

I. Field of the Invention

This invention relates to pouring spouts for material containers and, inparticular, to a flexible pouring spout having a container cover moldedaround the peripheral edge of the spout with its tamper-evident ring toprovide dual evidence of tampering with the container closure.

II. Description of the Prior Art

For many years, flexible pouring spouts have been used on industrialcontainers to facilitate repeated closure of the container using a capmember while also providing means for pouring material from thecontainer. The spout is nested within the closure to form a low profileallowing stacking of the containers. As necessary, the spout may bepulled out to create a pouring spout for the container. One widely knownspout is constructed of a low density polyethylene (LDPE) providingflexibility while the cap member threadably secured to the spout isconstructed of a high density polyethylene (HDPE).

While the closure members have been regularly improved to incorporatenew features, mounting of the closure within the container lid has posedproblems related to quality control and product integrity. In onewell-known method, a metal ring is used to secure the spout within thecontainer lid. The spout is positioned within an opening in thecontainer cover. The metal ring is crimped over the outer peripheralflange of the spout to hold the spout within the cover. However, theintegrity of the container is left to speculation because the closurecan be removed and replaced without detection. Efforts to overcome thisdisadvantage have included ultrasonically welding the closure within thecontainer cover. Although essentially bonding the closure to the lid,this product has not been widely accepted because of problems with therepeatability of the process, high capital expenditures, maintenance onthe tooling and product limitations. Both of these methods for securinga closure within a container cover have additional disadvantagesassociated with added material costs, capital expenditures for insertionmachinery, and recovery or recycling costs of multiple componentcontainers.

SUMMARY OF THE PRESENT INVENTION

The present invention overcomes the disadvantages of the prior knowncontainer closures by providing a pouring spout with an outer tamperevident ring which are both integrally molded within the container coverduring molding of the cover.

The closure spout of the present invention generally includes a flexiblespout, a cap member removably threadably mounted to the spout, and anintegrally molded tamper-evident ring removably secured to the capmember. The spout is preferably molded of a synthetic material such aslow density polyethylene (LDPE) which allows the spout to be repeatedlyextended and nested within the closure. An internal tamper evidentdiaphragm is molded within the spout for removal upon use of the spout.The cap and tamper evident ring are molded of a synthetic material suchas high density polyethylene (HDPE). A series of frangible elementsconnect the tamper ring to the cap. Upon threadably connecting the capwith the tamper ring to the spout, outer peripheral flanges of the spoutand tamper ring are flushly engaged.

The closure is integrally molded within the container lid upon moldingof the lid itself creating a permanent bond between the lid and theclosure. Specifically, the container lid is molded to the peripheralflange of the spout and tamper ring. The closure is inserted within themold for the container cover such that the peripheral flange of thespout and tamper evident ring extend into the mold cavity. As a result,upon molding the container lid, the heat and pressure of the resincreating the lid will envelope and bond to the peripheral flange of thetamper ring and spout. The integrally molded closure cannot be removedfrom the container cover without clearly damaging the container and/orthe closure itself includes dual evidence of tampering: the internaldiaphragm of the spout and the external tamper ring of the cap member.

A unique mold structure is utilized to mold the closure within thecontainer cover while preventing the molten plastic from flowing pastthe mold walls over the closure. Additionally, the closure flangeincorporates structural features which, in connection with the mold,slow the flow of molten plastic against the inserted closure to preventdeformation during molding of the container cover. The mold cavityincludes a diverter bead disposed outside the periphery of the closureto reduce the flow and pressure of the molten plastic at the interfacewith the flange while also ensuring uniform flow of molten plasticaround the closure. Also incorporated into the mold are pinch beadswhich provide localized clamping against the inserted closure to preventdistortion and movement of the closure. The prior molded closureincludes structural components to prevent distortion during insertmolding including a flow wall formed at the peripheral edge of theclosure flange to prevent the flow of molten plastic between the flangesfor the spout and tamper ring. Also molded into the outer periphery ofthe flange for the spout is a skirt support, a mass of plastic materialto restrict movement and distortion of the outermost edge of the closureunder the clamping forces of the mold. Each of these features preventdeformation and distortion of the closure as the container cover isintegrally molded therewith.

An additional feature of the present invention are improved bail tabsfor removal of the cap member. The tabs are extended and include anundercut for easier access by the user.

Other objects, features and advantages of the invention will be apparentfrom the following detailed description taken in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE INVENTION

The present invention will be more fully understood by reference to thefollowing detailed description of a preferred embodiment of the presentinvention when read in conjunction with the accompanying drawing, inwhich like reference characters refer to like parts throughout the viewsand in which:

FIG. 1 is a perspective view of a portion of a container with acontainer cover having a closure embodying the present invention;

FIG. 2 is a perspective view of the closure;

FIG. 3 is a cross-sectional view of the closure within the containercover;

FIG. 4 is an enlarged cross-sectional view of the peripheral flange ofthe closure being molded to the container cover;

FIG. 5 is an enlarged cross-sectional view of the closure molded withinthe container cover;

FIG. 6 is a cross-sectional view of the closure within a mold for thecontainer cover; and

FIG. 7 is an enlarged cross-sectional view of the closure within themold for the container cover.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION

Referring first to FIG. 1, there is shown an upper portion of acontainer 10 having a container cover or lid 12 to maintain the materialwithin the container 10. In a well known manner, the cover 12 is securedto the container 10 along a lip 14 of the container 10 after filling ofthe container 10. Typically, the container 10 and container cover 12 aremolded of a plastic material preferably a high density polyethylene(HDPE). In order to facilitate removal of the material from thecontainer 10, a closure 20 is formed in the container cover 12 whichallows the material to be poured or pumped from the container 10. Thepresent invention will be described in conjunction with a pouring spoutclosure 20 although it is to be understood that the specific type ofclosure may be interchanged in accordance with the present invention.

Referring now to FIGS. 2 and 3, the closure 20 is shown molded directlywithin the container cover 12. The closure 20 generally includes anestable spout 22 and a cap member 24 having a tamper-evident ring 26.The spout 22 and the cap member 24 with its tamper ring 26 are typicallymolded separately. Preferably, the spout 22 is molded of a low densitypolyethylene (LDPE) to provide flexibility while the cap 24 and ring 26are molded of a high density polyethylene (HDPE). Prior to insertionwithin the cover 12, the cap member 24 is threadably attached to theflexible spout 22.

The flexible spout 22 has a throat portion 28, which includes externalthreads 30, a flexible neck portion 32 and an outer peripheral flange34. Molded within the throat portion 28 of the spout 22 is a removablediaphragm 36 which provides internal tamper evidence for the closure 20.The diaphragm 36 has a pull ring 38 or other grasping means which allowsit to be torn out of the spout 22 by the user. In the event thediaphragm 36 is missing or partially torn from the interior of the spout22, this provides a visual indication to the user that the materialwithin the container 10 may have been tampered with. The flexible neckportion 32 allows the spout 22 to be selectively moved between thenested position shown in FIG. 2 and an extended position whereby thespout 22 extends beyond the plane of the cover 12 to facilitate thepouring of material from the container 10.

The cap 24 comprises a planar top 40 having a cylindrical portion 42extending therefrom. The cylindrical portion 42 has internal threads 44to cooperate with the threads 30 of the spout 22. In a preferredembodiment, the cap 24 includes bail handles 46 with bail tabs 48 tofacilitate removal of the cap 24 from the spout 22 by forming a handlefor rotation of the cap 24. The bail tabs 48 extend outwardly andinclude an angled undercut 50 to allow easier access to the bail handles46. The extended and undercut bail tabs 48 allow the user to positiontheir fingers beneath the bail tabs 48 to lift the bail handles 46 sothat the cap 24 may be rotated off of and on to the spout 22 asnecessary.

Molded as part of the cap member 24 is the tamper evident ring 26. Thetamper ring 26 is connected to the cap 24, specifically the bail handles46 by a plurality of frangible elements 52 circumferentially spacedabout the cap 24. The tamper ring 26 includes an annular ring 54 and aperipheral flange 56, the annular ring 54 having the frangible elements52. Upon assembly of the cap 24 with the tamper ring 26 to the spout 22,the peripheral flange 56 of the tamper ring 26 lies in flush engagementwith the peripheral flange 34 of the spout 22 as best shown in FIGS. 4and 5. The tamper ring 26 provides an external visual indicator ofremoval of the cap 24. Raising the bail handles 46 to remove the cap 24will cause the frangible elements 52 to break providing a clearindicator that the cap 24 may have been removed.

In a preferred embodiment of the present invention, the assembledclosure 20, comprising the spout 22, the cap 24 and tamper evident ring26, is molded directly within the container cover 12. The cover 12 ismolded such that it envelopes the peripheral flanges 34,56 of theclosure 20 to integrally combine the spout 22, tamper ring 26 and cover12 as shown in FIGS. 4 and 5. During molding of the cover 12, theassembled closure 20 is positioned within the mold 100 for the cover 12such that the closure 20 forms a barrier for one portion of the mold100. The mold 100 is sealed off against the peripheral flange 34,56 ofthe closure 20. As the molding material is injected into the cover mold100, the molten material will flow over and around the flanges 34,56 toencapsulate the flanges of the closure 20 and permanently join the spout22, tamper ring 26 and cover 12. The heat and pressure of the resin asthe cover 12 is molded creates an integral bond at a molecular levelwith the flanges 34,56.

In the positioning of flange 56 relative to flange 34, it will be seenas illustrated in FIGS. 4 and 5 that flange 34 extends radiallyoutwardly beyond outer edge 58 of flange 56. Additionally, flange 34 isconfigured with anchoring projections 62 and 64.

FIGS. 6 and 7 disclose a specific mold and closure configuration whichmaintains the integrity of the premolded closure 20 under the pressureand temperature extremes of the injection molding process for thecontainer cover 12. Prior to molding the cover 12, the closure 20,combining the flexible spout 22, the tamper ring 26, and the cap 24, ispositioned within the mold 100 for the container cover. The mold 100preferably includes an upper mold 102 and a lower mold 104 which combineto form an inner cavity 106 within which the closure 20 is positionedand an outer cavity 108 defining the configuration of the cover 12. Theinner cavity 106 and outer cavity 108 are separated by the insertedclosure 20 which is clamped into position by the mold portions 102,104.With the closure 20 clamped within the mold 100, molten plastic may beinjected into the cavity 108 to integrally bond the closure 20 withinthe container cover 12.

In order to ensure that the plastic is injected into the cavity 108 ofthe mold 100 and does not flow past the clamped closure 20 or otherwisedeform the premolded closure 20, specific features have beenincorporated into both the mold 100 and the inserted closure 20. Themold 100 includes an annular diverter flange 110 which forms arestricted passageway 112 around the outer periphery of the closure 20to slow and spread the flow of molten plastic around the mold cavity108. As molten plastic fills the portion of the cavity 108 peripherallyoutside of the diverter flange 110 increased pressure forces the plasticthrough the passageway 112 such that the resin comes in contact with theentire circumference of the closure 20 simultaneously. It has been foundthat without the diverter flange 110, the plastic resin engages theclosure 20 closest to the mold inlet and localizes heat and pressure inone area of the closure. The diverter flange 100 ensures substantiallyuniform enveloping of the flanges 34,56 of the closure 20.

The mold 100 also includes opposing clamp flanges 114,116 topositionally capture the inserted closure 20 between the mold halves102,104. Each of the clamp flanges 114,116 is provided with at least onepinch bead 118 extending annularly along the flanges 34,56. The pinchbeads 118 localize the clamping pressure in order to maintain theclosure 20 in place reducing the tendency to distort as a result ofpressures from the molten resin. These pinch beads 118 will "bite" intothe flanges 34,56 to retard movement.

The closure 20 itself is provided with features designed to overcome thedistortion affects associated with the pressures and temperatures of theinjected molten plastic. Formed at the outer periphery of the spoutflange 34 is an annular blocker bead 120 extending upwardly toessentially block the seam between the flanges 34,56 preventing resinfrom flowing between the spout 22 and the ring 26. It has beendetermined that as the molten plastic flows toward the closure 20, ittends to separate the two pieces. The blocker bead 120 blocks theinitial blast of resin reducing the force of the gap between the flanges34,56. Also formed at the outer periphery of the spout flange 34 is askirt mass 122 which provides additional material to the peripheraledge. This skirt 122 restricts movement and distortion of the edge ofthe closure 20 under the clamping forces of the mold 100 and theinjected molten resin.

In order to prevent movement of the tamper ring flange 56 relative tothe spout flange 34, an annular tongue 124, is provided on flange 34.Upon joining the flanges 56,34, the annular tongue 124 will engage orbite into the flange 56. This reduces lateral movement between thecomponents. Furthermore, because the tongue 124 and groove 126 areformed proximate the pinch beads 118, clamping of the components isimproved to prevent relative movement of the components while alsopreventing molten plastic from flowing between the flanges 34,56.

Thus, the present invention integrally combines the tamper evident ring26 with the container cover 12 providing an end product for the userwhich has dual tamper evidence. The removable tear-out diaphragm 36 ofthe spout 24 provides internal tamper evidence while the molded-intamper evident ring 26 provides visual external tamper evidence. Theintegral bond formed by the insert molding process creates a leak-proofcover 12 for the container 10 which is simpler and less expensive tomanufacture since the closure 20 is inserted during molding of the cover12.

The foregoing detailed description has been given for clearness ofunderstanding only and no unnecessary limitations should be understoodtherefrom as some modifications will be obvious to those skilled in theart without departing from the scope and spirit of the appended claims.

What is claimed is:
 1. In an integrally formed component of a containerwhich includes a preform and a component body integrally bonded to saidpreform, said preform including a spout member forming a passageway andhaving a peripheral flange, wherein the improvement comprises:saidpreform further including a tamper-evident ring having a peripheralflange disposed in adjacent relationship with said peripheral flange ofsaid spout member, such that the integral bonding of said component bodyto said preform includes bonding to said tamper-evident ring.
 2. Theintegrally formed component of claim 1 which further includes a capmember threadedly mounted to said spout member to selectively close saidpassageway.
 3. The integrally formed component of claim 2 wherein saidtamper-evident ring is detachably connected to said cap member by aplurality of frangible elements.
 4. The integrally formed component ofclaim 3 wherein the peripheral flange of said tamper-evident ring has anouter edge and wherein the peripheral flange of said spout memberextends in a radial direction beyond said outer edge.
 5. The integrallyformed component of claim 4 wherein said spout member includes internaltamper-evidence means blocking said passageway.
 6. The integrally formedcomponent of claim 5 wherein said internal tamper-evidence means is adiaphragm removably mounted within said passageway.
 7. The integrallyformed component of claim 6 wherein the flange of said spout memberincludes an anchoring projection.
 8. The integrally formed component ofclaim 1 wherein the peripheral flange of said tamper-evident ring has anouter edge and wherein the peripheral flange of said spout memberextends in a radial direction beyond said outer edge.
 9. The integrallyformed component of claim 1 wherein said spout member includes internaltamper-evidence means blocking said passageway.
 10. The integrallyformed component of claim 9 wherein said internal tamper-evidence meansis a diaphragm removably mounted within said passageway.
 11. Theintegrally formed component of claim 1 wherein the flange of said spoutmember includes an anchoring projection.